Well its finally time I finished this, before the London ComiCon, so here's the last couple days' work:
With the help of Ma Fett, we dyed the jumpsuit and hoses (graciously sent by zxwing). looks a little purple-er in person, but I think its pretty close
The biggest issue I've had has been the Gauntlets. They were a lot of work, but once I got into it, I had a lot of fun making them. Got a set of RotJ gauntlets from Ruffkintoy, sliced off the keypad holder and filled the gap with sintra and milliput. I had to scratch build the flamethrower, as the RotJ one was way too long for Jango, turns out mine is a little too short, but I don't mind. Well, since my gauntlets have such nice shiny buttons on them, I just had to use them, so the helmet was completely re-wired, and with the help of some spare cable, I have my batteries, and switches, and controls in the gauntlets.
The Atari switch has 2 sets of poles, so that turns my mic on/off, as well as the red LED next to it. The two toggle switches control my two fans, with a battery for each in each arm. the two momentary push switches on the flamethrower are wired up to my shoulder, but currently aren't attached to anything. It was a PITA to put on through the jumpsuit, the 4-pole stereo jacks I was using kept coming out, so with the canibalism of an old bag, I attached some clips to hold it firmly in place.
Finally, the Resin Parts were screwed, and glued, then filled and sanded to look b-e-a-utiful. They primed(again) and sprayed silver. I'll go over some of the bits with rub-n-buff-n-buff-n-buff to make it a bit shinier.
BTW, I think the hoses took too much purple, and not enough blue... is it passable?
Special thanks to all the guys I met at Pittsburgh ComiCon, for giving me the motivation to finish.
-Adam